Furniture and countertop edge molding attachment system and method for its use

ABSTRACT

An assembly and method for its use that provides a strong and efficient way of attaching a decorative molding component to a countertop unit or similar furniture piece. The countertop unit consists of a countertop core component with a countertop edge piece that is pre-attached to its unfinished edge before application of a countertop finish surface material. The countertop edge piece has a specially configured groove pre-cut in its bottom surface which in turn creates a wedge-shaped tongue. The decorative molding component has a unique “J”-shaped attachment side with a tongue and groove of its own that interlocks and wedges with the tongue and groove in the countertop edge piece portion of the countertop unit. The interlocking action of this assembly and methodology eliminates the need for clamping while still providing both a tighter fit between components and a precise method for adjusting and aligning component surfaces.

BACKGROUND OF THE INVENTION

1. Field of Invention

The present invention relates to the construction and attachment ofdecorative and/or wear-resistant edges to countertops and other similarfurniture components.

2. Background of the Prior Art

This inventor's previous U.S. Pat. No. 6,343,454 issued Feb. 5, 2002which is incorporated in its entirety herewith by reference, describesan improved method of construction and attachment of decorative edges tocountertops and similar furniture components.

While the method of construction and attachment provided by U.S. Pat.No. 6,343,454 works well and represents a major improvement over theprior art, it does nevertheless require a level of machining precisionthat is not always available to the countertop/furniture fabricator inthe field. In the case of the molding component itself, this problem isminimal since this molding component is generally pre-manufactured by afirm that produces the product in sufficient quantities to readilyjustify the investment in machinery that will allow for production of aconsistent, strong and aesthetically pleasing product per theconfiguration described in U.S. Pat. No. 6,343,454. Indeed thisdecorative molding art exists primarily because the production of manysuch edge pieces cannot be cost effectively done by those who fabricateand install countertops or other furniture components in the field—i.e.,it is a specialty product.

The machining problem is more evident with regard to the preparation ofthe countertop core for receipt of the molding component. As describedin detail in U.S. Pat. No. 6,343,454, a specially configured groove iscut in the bottom surface of the countertop core. The groove in turnproduces a downward facing, wedge-shaped tongue at the countertop coreedge. If this groove is to be machined into the countertop core itself,then, it is done by the countertop fabricator or installer in the fieldand must be done in a manner that will be precise enough to allow forproper installation of the pre-manufactured decorative edge moldingpiece. While this machining operation is not particularly complex, itcan be tedious or cumbersome for the typical fabricator or installer,given the length and size of countertop sections. Significantinconsistencies in this machining operation, will reduce or negate theadvantages of the methodology described in U.S. Pat. No. 6,343,454 andresult in problems similar to those involved in earlier forms of theart.

Another problem that must be recognized, relates to the composition ofthe countertop core. In most cases, this core is composed of either acomposition product such as particle board or of plywood. In eithercase, the wedge-shaped tongue produced by the groove required forattachment of the decorative edge component per U.S. Pat. No. 6,343,454may be weaker than necessary to withstand the pressure that is appliedwhen the decorative edge molding piece is being installed. This maycause the tongue to break off the countertop core thereby defeating theadvantages of the U.S. Pat. No. 6,343,454 methodology.

It should be noted that the above described problem of countertop corestrength only relates to the decorative edge installation process. Ifthe groove is properly cut and adhesive is applied on each groove andtongue surface as described in U.S. Pat. No. 6,343,454, the countertopcore will be an integral, functionally strong, unit once the adhesivehas dried.

SUMMARY OF THE INVENTION

The present invention corrects the above described problems associatedwith the installation and attachment of decorative edge molding whenusing the U.S. Pat. No. 6,343,454 configuration and methodology byproviding a separate pre-manufactured, countertop core edge piece. Inthe preferred embodiment, the countertop core edge piece is manufacturedby the maker of the molding component thereby allowing for the matchingof these pieces. These pieces are then provided as a set to thecountertop fabricator or installer, thus eliminating the need for anyrelated field machining operations.

Alternatively, in cases where the countertop edge piece is not suppliedby the molding component manufacturer, it is much easier for the fieldfabricator or installer to properly machine this piece because thecountertop edge piece as provided by the current invention is farsmaller and less cumbersome than the countertop core component.Furthermore, since the countertop edge piece is seldom a visible part ofthe finished countertop/furniture product, it is possible to make it inlengths shorter than the length of the molding component itself withoutdetracting in any way from the aesthetic quality of the finishedproduct. These shorter countertop edge pieces are applied separately,with ends abutting one another, to the unfinished edge of the countertopcore component further easing their fabrication and installation.

Regardless of the manufacturer of the countertop edge piece, it can bemade from material, different from, and stronger than, that of thecountertop core component. The material can be selected for its strengthwhich prevents failure during the installation of the molding component.

Because of the features outlined above, this invention greatlysimplifies and expedites the work associated with fabrication ofcountertops or other furniture components where the U.S. Pat. No.6,343,454 methodology is utilized.

The furniture and countertop edge molding attachment system and methodfor its use comprises a countertop core component, a countertop edgepiece, a decorative edge molding component and the countertop surfacematerial. In some cases, the countertop core component may alsoconstitute the countertop surface material.

The countertop core component has an upper surface, a bottom surface,and an unfinished edge.

The method of the present invention involves 1) creating a separatecountertop edge piece that is generally rectangular and has a topsurface, a bottom surface, a front face, and a rear face. The countertopedge piece has a first groove with an angled wall cut in its bottomsurface. This groove in turn creates a downwardly facing wedge-shapedtongue between its angled front wall and the front face of thecountertop edge piece. The configuration of the countertop edge piecegroove and wedge-shaped tongue are identical to those described indetail in U.S. Pat. No. 6,343,454 except that they are machined into thecountertop edge piece bottom surface and not into the bottom surface ofthe countertop core component.

The second step of the method involves 2) attachment of the countertopedge piece to the front unfinished edge of the countertop core componentsuch that the rear face of the countertop edge piece is in abuttingrelationship with the unfinished edge of the countertop core componentand the upper surface of the countertop edge piece is flush with theupper surface of the countertop core component. Attachment of thecountertop edge piece to the countertop core component may be done inany manner that produces a strong bond as long as the attachment methoddoes not obstruct the countertop edge piece groove or the countertopedge piece wedge-shaped tongue.

After the countertop edge piece has been attached to the countertop corecomponent with their upper surfaces flush, the third step of the methodinvolves 3) application of the countertop surface material as a singlepiece over the top of the countertop core component and the top surfaceof the countertop edge piece with the front edge of the countertopsurface material being made flush with the front face of the countertopedge piece.

At this point, the unit created by the attachment of the countertop edgepiece to the countertop core component and the application of thecountertop surface material is equivalent to the countertop componentupon completion of step 1) as described in the summary of invention forU.S. Pat. No. 6,343,454.

The molding component as described in U.S. Pat. No. 6,343,454 is thenattached to the countertop component by following steps 2) thru 4) asdescribed in the summary of invention for that patent.

It is a feature of the present invention to provide a countertop orfurniture assembly that is easier to fabricate and install withcommensurate potential for improvement in aesthetic quality.

A significant advantage of the present invention is to provide a betterfit between the molding component and the countertop component ofdecorative countertops and furniture by increasing the accuracy andreliability of the machining operations required for the attachment ofthe molding component to the countertop component.

A further advantage of the current invention is the increased ease ofmachining of the countertop edge piece because of its smaller, lesscumbersome size when compared with machining operations on wholecountertop core components.

A further advantage of the current invention is the avoidance ofmaterial failure by strengthening of the prepared countertop componentthrough use of a countertop edge piece that can be separately fabricatedfrom stronger material.

The above and other objects, features and advantages of the presentinvention will become apparent from the drawings, the description givenherein and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective sectional view of a complete countertop assemblyconfigured in accordance with the preferred embodiment of the currentinvention.

FIG. 2 is an exploded perspective view showing the parts andconstruction of a countertop unit prior to installation of thedecorative molding component.

FIG. 3 is a perspective sectional view of the countertop edge piece

FIG. 4 is a perspective sectional view of a molding component configuredin accordance with U.S. Pat. No. 6,343,454 and suitable for use with thecurrent invention.

FIG. 5 illustrates the dimensional relationships between the componentparts of the current invention.

FIG. 6 illustrates the attachment methodology for assembly of themolding component to the countertop unit when using the presentinvention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to the drawings, FIG. 1 illustrates the completedcountertop assembly of the present invention which is designated by thenumeral 10. The countertop assembly 10 is composed of the countertopcore component 20, a molding component 30 with a decorative face 35, acountertop surface material 40 and a countertop edge piece 50.

Referring to FIG. 2, the countertop unit 60 includes a countertop corecomponent 20 made from any appropriate material such as particle boardor plywood and having an upper surface 21, a lower surface 22, and anexposed unfinished side edge 23; a countertop edge piece 50 which is agenerally rectangular member made from any appropriate material such ashardwood and having a top surface 51, a rear face 52, a front face 53,and a bottom surface 54; and a countertop surface material 40, whosefront edge 41 is made flush with the front face 53 of the countertopedge piece 50 when the countertop unit is assembled. The countertop edgepiece 50 has a groove 55 cut in its bottom surface 54 which is oppositethe top surface 51 to which the countertop surface material 40 isbonded. The groove 55 runs parallel to the front face 53 of thecountertop edge piece to which the decorative edge molding component 30(FIG. 1 and FIG. 4) will be attached.

FIG. 3 illustrates a perspective sectional view of the countertop edgepiece 50 and the groove 55 cut in its bottom surface 54. The front wall55 a of groove 55 is not perpendicular to the bottom surface 54 ofcountertop edge piece 50 rather it is angled slightly in the range of 3to 5 degrees so that it is closer to the front face 53 of the countertopedge piece 50 at its mouth (bottom surface 54 of edge piece 50) than itis at its roof 55 b. In the preferred embodiment of the currentinvention, the rear wall 55 c of groove 55 is perpendicular to thebottom surface 54 of countertop edge piece 50. Alternatively, in thesecond embodiment of the current invention, the groove rear wall 55 a isnot perpendicular to the bottom surface 54 of the countertop edge piece50 but is also angled to make it parallel to the groove front wall 55 awhich is angled as described in all cases.

As can be seen in FIG. 3, creation of groove 55 in turn creates adownward facing wedge-shaped tongue 56 whose front face is the lowerportion of front face 53 of the countertop edge piece 50 and whose rearside is the angled front wall 55 a of groove 55 and whose tongue end isthe remainder of bottom surface 54 that lies between groove 55 and thefront face 53 of the countertop edge piece 50.

Note that FIG. 4 and its description are included herein for continuityand ease of reference only. The FIG. 4 molding component, and itsdescription below, is identical to the molding component described inU.S. Pat. No. 6,343,454 and is not changed by the present invention.

FIG. 4 illustrates a perspective drawing of the molding component 30including a decorative front side 35. There are many shapes for thedecorative front side of a molding component. For example, some may bebeveled on top with a flat face such as the one shown in FIG. 4. Inother cases, the decorative side may be square or a full half round orsome other decorative profile. Similarly, the finish surface of thedecorative front side 35 varies. Examples include varnished wood,plastic laminate, or solid polymer. It should be recognized that neitherthe shape of the decorative front side 35 nor its finish are subjects ofthe current invention. What is important is that the top edge 36 wherethe finished side 35 meets the flat back joining side 37 is straight andwell defined thereby allowing it to fit tightly against the front face53 (see FIG. 2) of the countertop edge piece 50 while also allowing itto be aligned with the countertop surface material 40 during finalassembly.

Referring again to FIG. 4, the core 33 of molding component 30 althoughshown as 3 pieces for clarity and definition, may, alternatively bemilled from one or two pieces of material such as medium densityfiberboard, solid wood or solid polymer.

As shown in FIG. 4, the joining side of the molding component 30 is a“J” shape consisting of a flat back joining surface 37 that extends downfrom the top edge 36 of the molding component decorative side 35 tobottom point 37 a.

As FIG. 4 illustrates, a spacer piece 33 a extends rearward from thelowest point 37 a on the flat back joining surface 37 and serves to holdan upward facing tongue 33 b away from the flat back joining surface 37.The faces 31 and 32 of the upward facing tongue 33 b are parallel to theflat back joining surface 37. At the same time, spacer piece 33 a alsocreates a groove. 38 above its upper face 39 and between the front face31 of the upward facing tongue and the flat back joining surface 37. Ascan be seen, the groove is open at the top

Referring to FIG. 5, the height D5 of the flat back joining surface 37of molding component 30 as measured from the uppermost finished edge 36to the intersection 37 a of the flat back joining surface with the top39 of spacer piece 33 a is slightly greater than the total thickness D2of the countertop unit 60 unfinished front edge which equals the heightof the front face of the countertop edge piece 53 plus the thickness ofthe countertop surface material 41. The spacer portion 33 a of moldingcomponent 30 is rectangular and serves to hold the upward facing tongue33 b, which is also rectangular, away from and parallel to the flat backjoining surface 37 of the molding component. The width D6 of the spacerportion 33 a and the upward facing groove 38 it creates is substantiallyequal to the midpoint thickness D7 of the downward facing tongue 56 ofthe countertop edge piece 50. The width D4 of the upward facing tongue33 b is substantially equal to the width D3 of the roof 55 b of downwardfacing groove 55 of countertop edge piece 50. The effective height D8 ofthe upward facing tongue 33 b on the molding component 30 is slightlyless than one half D2. The depth D1 of countertop edge piece groove 55is substantially equal to one half the countertop unit edge thicknessD2. Countertop edge piece groove 55 front wall 55 a is at an angle “a”which is in the range of about 3 to 5 degrees from perpendicular to thebottom surface 54 of the countertop edge piece 50. In the firstembodiment of the current invention, the rear wall 55 c of groove 55 incountertop edge piece 50 is perpendicular to the bottom surface 54 ofcountertop edge piece 50. In the second embodiment of the currentinvention, rear wall 55 c is parallel to the angled front wall 55 a ofgroove 55.

FIG. 6 illustrates the assembly methodology for a complete countertopconfigured in accordance with the present invention. Prior to assembly,the countertop edge piece 50 has a groove 55 cut in its bottom surfaceas shown in FIG.3. The construction of the countertop unit involvesattachment of a countertop edge piece 50 to a countertop core 20 suchthat the rear face 52 of the countertop edge piece 50 is in abuttingrelationship with the front edge 23 of the countertop core 20 and thetop surface 51 of countertop edge piece 50 is flush with the top surface21 of the countertop core 20. Attachment of the countertop edge piece 50to the countertop core 20 may be by any means such as gluing, screwing,nailing, stapling or some combination thereof provided that the methodof attachment is sufficiently strong and does not obstruct either thedownward facing groove 55 or the downward facing wedge-shaped tongue 56of the countertop edge piece 50.

After the countertop edge piece 50 has been attached to the countertopcore 20, the countertop surface material 40 is then applied as shown inFIG. 2.

FIG. 4 illustrates the configuration of the molding component and FIG. 5provides additional dimensional relationships for the proper fitting ofthe components of the present invention.

When ready for assembly, a thin coat of glue or other adhesive with areasonable open time, say 30 minutes, is applied to the countertop unitunfinished front face 63 and the molding component 30 flat back joiningsurface 37. A bead of glue or adhesive is run in the bottom of themolding component upward facing groove 38 and on the on the top edge 39of its upward facing tongue 33 b. After application of the glue oradhesive, molding component 30 is placed below the countertop unit 60 sothat its flat back joining surface 37 is parallel to and in planaralignment with the countertop unit's unfinished front face 63. Themolding component 30 is then raised vertically until the upward facingtongue 33 b of the molding component 30 enters the downward facinggroove 55 of the countertop edge piece and the downward facing tongue 56of the countertop edge piece 50 enters the upward facing groove 38 ofthe molding component 30. As the molding component 30 is raised further,the uppermost forward edge 39 a of upward facing tongue 33 b of themolding component 30 contacts the rear angled face 55 a of the downwardfacing tongue 56 of the countertop edge piece 50 . Once contact is made,further raising of the molding component 30 wedgeably forces upwardfacing tongue 33 b back away from the unfinished face 63 of thecountertop unit 60 which in turn forces the flat back joining surface 37of molding component 30 tighter and tighter against the countertop unit60 unfinished face 63. By the time the top edge 36 of molding component30 is aligned with the top finished surface 40 of the countertop unit60, the molding component 30 and the countertop unit 60 are firmly andtightly wedged together. Despite the tightness of this clamping action,as long as the glue or adhesive is wet, the molding component can stillbe adjusted up or down sufficiently to ensure proper alignment ofmolding component top edge 36 with countertop component surface 40.

As the molding component 30 is raised into position, the beads of glueor adhesive applied to the molding component groove 38 and upward facingtongue 33 b are forcibly distributed, filling grooves 38 and 55 andcovering tongues 33 b and 56.

1. An assembly comprising: a countertop core component having anunfinished edge, an upper surface, and a lower surface; a countertopedge piece that is a generally rectangular member having a top surface,a bottom surface, a front face, and a rear face, with an angled firstgroove disposed in its bottom surface which in turn creates a downwardfacing wedged-shaped tongue between the first groove and the front faceof said countertop edge piece; a countertop surface material coveringboth the upper surface of the countertop core component and the uppersurface of the countertop edge piece; and a molding component as havinga decorative front side with a top edge and a rear J-shaped attachmentside with a flat back joining surface, an upwardly facing groove and anupwardly facing tongue.
 2. The assembly as in claim 1 wherein said firstgroove of said countertop edge piece has a front wall that is proximatethe front face of said countertop edge piece and said front wall beingoffset from perpendicular to said countertop edge piece bottom surfaceby an angle in the range of about 3 to 5 degrees such that a roof ofsaid first groove is narrower than a mouth thereof.
 3. The assembly asin claim 1 wherein said first tongue of said countertop edge piece iswedge-shaped with the wedge shape being created by the angled front wallof said first groove in said countertop edge piece which said firstgroove front wall also constitutes said rear face of the downward facingfirst tongue and said front face of said downward facing first tonguebeing a lower portion of said front face of said countertop edge pieceitself and a tip of said first tongue being a forward remainder portionof said bottom surface of said countertop edge piece after said firstgroove is cut.
 4. The assembly as in claim 1 wherein said first grooveof said countertop edge piece has a rear wall that is proximate saidcountertop edge piece rear face and said rear wall is generallyperpendicular in relationship to said countertop edge piece bottomsurface.
 5. The assembly as in claim 1 wherein said first groove frontwall and first groove rear wall of said countertop edge piece are joinedby a groove roof which is generally parallel to said countertop edgepiece bottom surface.
 6. The assembly as in claim 1 wherein the depth ofsaid first groove of said countertop edge piece is substantially equalto ½ the sum of the height of the front face of said countertop edgepiece plus the thickness of said countertop surface material.
 7. Theassembly as in claim 1 wherein said countertop core component is made ofparticle board, plywood, medium density fiberboard, solid wood or solidsurface material.
 8. The assembly as in claim 1 wherein said countertopsurface material is made of plastic laminate, solid surface material,veneer, paint or varnish finish
 9. The assembly as in claim 1 whereinsaid top edge of said molding component has its said decorative sidemeets a joining side such that said top edge can be made flush with saidcountertop surface material along its entire length.
 10. The assembly asin claim 1 wherein said molding component has a generally J-shapedprofile on its attachment side, said J-shaped profile comprised of: aflat back joining surface that extends down from said top edge for adistance that is slightly greater than the total thickness of the heightof said front face of said countertop edge piece plus the thickness ofsaid countertop surface material; and an L-configuration extendingrearward from the lowest point on said flat back joining surface andthen upward creating said tongue member having its faces parallel tosaid flat back joining surface and said upwardly facing groove createdbetween said front face of said upwardly facing tongue and said face ofsaid flat back joining surface.
 11. The assembly as in claim 10 whereinsaid tongue member of said molding component extends upward slightlyless than ½ the height of said flat-back joining surface and the widthof said tongue member being substantially equal to the width of saidfirst groove roof of said countertop edge piece.
 12. The assembly as in10 wherein the depth of said molding component upwardly facing groove isslightly greater than ½ the sum of the height of said front face of saidcountertop edge piece plus the thickness of said countertop surfacematerial and the width of said upwardly facing groove of said moldingcomponent is substantially equal to the median width of said downwardlyfacing tongue of said countertop edge piece.
 13. A method of assemblinga complete countertop comprising the steps of: providing a countertopcore component having a top surface, a bottom surface, and a frontunfinished edge; providing a rectangular countertop edge piece having atop surface, a bottom surface, a rear face and a front face, saidcountertop edge piece having a groove with an angled front wall cut inits bottom surface such that said groove in turn creates a downwardfacing wedge-shaped tongue between the front wall of said groove and thefront face of said countertop edge piece; providing a countertop finishsurface material made from plastic laminate, veneer, solid surfacematerial, paint or varnish; providing molding component having adecorative side, a top edge and a J-shaped joining side consisting of aflat back joining surface, an upwardly facing tongue and an upwardlyfacing groove; attaching said countertop edge piece to said countertopcore component unfinished front edge so that the rear face of saidcountertop edge piece is in abutting relationship with said unfinishedcountertop core component unfinished front edge and the upper surface ofsaid countertop edge piece is flush with said top surface of saidcountertop core component; applying the countertop finish surfacematerial over the top surface of said countertop core component and theupper surface of the countertop edge piece such that the front edge ofsaid countertop surface material is flush with the front face of thecountertop edge piece; applying glue or adhesive to said moldingcomponent flat back joining surface, said bottom of said moldingcomponent upward facing groove and said top edge of said moldingcomponent's upwardly facing tongue; attaching said molding component tothe front face of said countertop edge piece by lowering it enough toallow its flat back joining surface to be brought parallel to, and inplanar alignment with, the exposed front face of the countertop edgepiece and then raising the molding component so its upwardly facingtongue is inserted into the first groove of the countertop edge pieceand simultaneously inserting the downwardly facing tongue of thecountertop edge piece into the upwardly facing groove of the moldingcomponent; raising said molding component causing a wedging actionwhereby the angled back face of said countertop edge piece downwardlyfacing wedge-shaped tongue forces said upwardly facing tongue of saidmolding component back away from said front face of the countertop edgepiece while simultaneously forcing the flat back joining surface of saidmolding component tightly against the front face of said countertop edgepiece; and raising and adjust said molding component until its top edgeis flush and aligned with said countertop finished surface material.